Abstract:The effect of small tool pin profiles on the microstructures and mechanical properties of 6061 aluminum alloy joints using friction stir welding (FSW) technique was investigated. Three different tool pin profiles: threaded tapered cylindrical (T₁), triangular (T₂) and square (T₃) were used to produce the joints. The results indicate that the weld joints are notably affected by joining with different tool pin profiles. The triangular tool pin profile produces the best metallurgical and mechanical weld properties compared with other tool pin profiles. Besides, the lowest tensile strength and microhardness are obtained for the joint friction stir welded with square tool pin profile. It is observed that the smaller tool pin profile and shoulder diameter lead to narrow region of heat affected zone (HAZ) and a desired level of softening. The fracture surface examination shows that the joints are also affected when welding with different types of tool pin profiles. The fracture surface shows that the triangular specimen fails with a ductile fracture mode during the tensile test, while the brittle fracture modes are observed in the joints fabricated with other tool pin profiles (T₁ and T₃).

Key words: friction stir welding; small tool pin profile; mechanical properties; aluminum alloy; grain size